1989 FORD FIESTA engine

1 General information andprecautions
General information
The fuel system on all models with
carburettor induction comprises a rear-
mounted fuel tank, a mechanical diaphragm
fuel pump, a carburettor and an air cleaner. The fuel tank is mounted at the rear, under
the floorpan behind the rear seats. The tank
has a “ventilation-to-atmosphere system”
through a combined roll-over/anti-trickle fill
valve assembly, located in the left-hand rear
wheel arch. A filler neck sensing pipe, integral
with the fuel tank filler pipe, will shut off the
petrol pump filler gun when the predetermined
maximum level of fuel is reached in the tank,
so preventing spillage and wastage. A
conventional fuel level sender unit is mounted
in the top face of the fuel tank. One of two fuel pump types will be fitted,
depending on the engine type. On HCS
engines, the fuel pump is operated by a
pivoting rocker arm; one end rests on an
eccentric lobe on the engine camshaft, and
the other end is attached to the fuel pump
diaphragm. The pump fitted to the CVH
engine is operated by a separate pushrod,
one end rests on an eccentric lobe on the
engine camshaft, and the other rests on the
pump actuating rod which operates the
diaphragm. Both types of mechanical pump
incorporate a nylon mesh filter, and are of
sealed type (they cannot be serviced or
overhauled). Four different types of Weber carburettor
are featured in the range, further details being
given in later Sections of this Chapter. The air cleaner incorporates a “waxstat”
controlled air inlet, supplying either hot air
from a shroud mounted around the exhaust
manifold, or cool air from a duct in the front of
the vehicle.
Precautions
Warning: Petrol is extremely
flammable - great care must be
taken when working on any part of the fuel system. Do not smoke or allow
any naked flames or uncovered light bulbs
near the work area. Note that gas powered
domestic appliances with pilot flames,
such as heaters, boilers and tumble
dryers, also present a fire hazard - bear
this in mind if you are working in an area
where such appliances are present.
Always keep a suitable fire extinguisher
close to the work area and familiarise
yourself with its operation before starting
work. Wear eye protection when working
on fuel systems and wash off any fuel spilt
on bare skin immediately with soap and
water. Note that fuel vapour is just as
dangerous as liquid fuel; a vessel that has
just been emptied of liquid fuel will still
contain vapour and can be potentially
explosive. Petrol is a highly dangerous and
volatile liquid, and the precautions
necessary when handling it cannot be
overstressed.
Many of the operations described in this
Chapter involve the disconnection of fuel
lines, which may cause an amount of fuel
spillage. Before commencing work, refer
to the above Warning and the information
in “Safety first” at the beginning of this
manual.
When working with fuel system
components, pay particular attention to
cleanliness - dirt entering the fuel system
may cause blockages which will lead to
poor running.
Certain adjustment points in the fuel system
are protected by tamperproof caps, plugs or
seals. In some territories, it is an offence to
drive a vehicle with broken or missing
tamperproof seals. Before disturbing a
tamperproof seal, first check that no local or
national laws will be broken by doing so, and
fit a new tamperproof seal after adjustment is
complete, where required by law. Do not
break tamperproof seals on any vehicle whilst
it is still under warranty. Carburettors are delicate instruments, and
care must be taken not to disturb any
components unnecessarily. Before attempting
work on a carburettor, ensure that the relevant
spares are available; it should be noted that a complete strip down of a carburettor is
unlikely to cure a fault which is not
immediately obvious, without introducing new
problems. If persistent problems occur, it is
recommended that the services of a Ford
dealer or a carburettor specialist are sought.
Most dealers will be able to provide
carburettor rejetting and servicing facilities.
Where necessary, it may be possible to
purchase a reconditioned carburettor.
2 Air cleaner
-
removal and refitting
1
Note: Air cleaner element renewal and air
cleaner temperature control system checks
are described in Chapter 1.
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 On CVH engine models, pull free and
release the accelerator cable from the locating
clip on the side of the air cleaner.
3 Undo the two (HCS engine) or three (CVH
engine) retaining screws, and partially lift the
air cleaner from the carburettor so that the
hose and wiring connections to the underside
of the air cleaner body are accessible (see
illustration) .
4 Note their connections and routings, then
detach the wiring multi-plug and hoses from
the underside of the air cleaner (see
illustrations) . On CVH engines, also
disconnect the vacuum hose from the inlet
manifold.
5 Lift the air cleaner from the carburettor.
6 If required, the inlet air temperature sensor
can be unscrewed and removed from the
base of the air cleaner (where fitted).
Refitting
7 Refit in the reverse order of removal. Renew
any hoses that are perished or cracked, and
ensure that all fittings are securely and
correctly reconnected.
Fuel system – carburettor engines 4A•3
2.4b Disconnecting the intake air temperature sensor multi-plug
(CVH engine shown)2.4a Disconnecting the oil separator/
crankcase ventilation hose from the air
cleaner (CVH engine shown)2.3 Undoing the air cleaner retainingscrews (HCS engine shown)
4A
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3Accelerator cable (manual
transmission models) -
removal, refitting and adjustment
1
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Working inside the vehicle, disconnect the
cable from the top of the accelerator pedal,
release the grommet and pull the cable free
from the pedal. Withdraw the cable through
the engine side of the bulkhead.
3 Refer to Section 2 and remove the air
cleaner.
4 Detach the inner cable from the carburettor
linkage.
5 Prise free the retaining clip, detach the
outer cable from the support bracket, and
remove the cable (see illustrations) .
Refitting and adjustment
6To refit the cable, feed the inner cable
through the bulkhead, and reconnect the inner
cable to the accelerator pedal. Note that a
plastic sleeve is supplied with new cables for
the purpose of routing through the bulkhead
panel.
7 Locate the grommet in the bulkhead, then
push the outer cable into it to secure it in the
bulkhead.
8 Lubricate the cable grommet at the
carburettor end with a mild soapy solution, then reconnect the cable to the carburettor.
Locate the outer cable by pulling it towards
the rocker cover.
9
Have an assistant depress the accelerator
pedal fully, and hold it in this position. The
outer cable should be seen to move in its
grommet. Refit the securing clip to the
bracket, then release the accelerator pedal.
10 Depress the accelerator pedal, then
release it and check that the throttle opens
and shuts fully. Further adjust if necessary
before refitting the air cleaner and
reconnecting the battery.
4 Accelerator cable (CTX automatic transmission
models) - adjustment
4
The system for operating the throttle-plate
in the carburettor on CTX automatic
transmission equipped vehicles is completely
different to that employed on manual
transmission vehicles. The cable from the
accelerator pedal leads to a linkage
mechanism which is bolted to the
transmission housing. Two further cables lead
from this linkage mechanism, one of which
operates the throttle-plate in the carburettor. As all three cables have to be adjusted at
the same time, and access to a Ford special
tool is required, it is recommended that a Ford
dealer be entrusted with cable adjustments,
or renewal.
5 Accelerator pedal -
removal and refitting
1
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Peel back the carpet and insulation from
the driver’s footwell to allow access to the
accelerator pedal.
3 Detach the accelerator cable from the pedal
(see Section 3), then release the circlip from
the pivot shaft and remove the accelerator
pedal.
Refitting
4 Refit in the reverse order of removal. On
completion, check the action of the pedal and
the cable to ensure that the throttle has full
unrestricted movement, and fully returns
when released.
5 Reconnect the battery negative lead.
6 Choke cable - removal,
refitting and adjustment
1
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Refer to Section 2 and remove the air
cleaner.
3 Referring to Chapter 10, Section 20, for
further details and illustrations, remove the
choke control knob on the side of the steering
column shroud by pushing in the pin located
on the side of the knob and withdrawing.
4 Detach the steering column lower shroud,
disconnect the multi-plug from the choke
warning light switch/pull control assembly,
and unscrew the collar securing the
switch/pull control assembly to the shroud.
5 Disconnect the choke inner cable from its
location on the carburettor choke linkage,
then release the outer cable retaining clip (see
illustrations) .
6 Push the bulkhead panel grommet through
the bulkhead and remove the cable.
Refitting
7 Route the cable through the bulkhead then
secure the bulkhead panel grommet to its
location.
8 Reconnect the choke inner cable to its
location on the carburettor choke linkage.
9 Refit the choke warning light switch/pull
control assembly to the lower steering column
shroud and secure with the collar, then
reconnect the multi-plug.
10 Refit and secure the lower steering
column shroud, then refit the choke control
knob.
11 Pull the choke control knob to the fully-on
position. Hold the choke in the fully-on
4A•4 Fuel system – carburettor engines
6.5b Choke outer cable retaining clip
released6.5a Disconnect the inner cable from thechoke linkage
3.5b . . . then release from its support bracket3.5a Remove the accelerator outer cablesecuring clip . . .
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position at the carburettor, then secure the
outer cable with its retaining clip.
Adjustment
12To check that the choke cable is correctly
adjusted, the control knob must be pulled out
to the full-on position and the choke lever
must be in contact with its stop. Adjust as
required if necessary.
13 Press the choke knob fully in (to the off
position), then check that the choke linkage at
the carburettor has fully returned to its off
position and the choke valve plate in the
carburettor is at a right angle (90º) to the
venturi.
14 Refit the air cleaner.
15 Reconnect the battery, turn the ignition
on, operate the choke and check that the
choke warning light operates correctly.
7 Fuel pump -
testing, removal and refitting
2
Note: Refer to the warning note in Section 1
before proceeding.
Testing
1 Access to the fuel pump on HCS engine models is best gained from underneath the
vehicle
(see illustrations) . Apply the
handbrake, then raise and support it on axle
stands at the front end (see “Jacking and
vehicle support” ).
2 The fuel pump may be tested by
disconnecting the fuel feed pipe from the
carburettor, and placing the pipe’s open end
in a suitable container.
3 Detach the multi-plug from the DIS ignition
coil, or the LT lead from the negative terminal
of the ignition coil, to prevent the engine from
firing.
4 Actuate the starter motor. If the fuel pump
is in good working order, regular well-defined
spurts of fuel should eject from the open end
of the disconnected fuel pipe.
5 If this does not occur, and there is fuel in
the tank, the pump is defective and must be
renewed. The fuel pump is a sealed unit, and
cannot be repaired.
Removal
6 Two types of mechanical fuel pump are
fitted, the application depending on the
engine type. Some models may also be fitted
with a fuel vapour separator (see illustration) ;
if this is removed, its hoses should be labelled
to avoid the possibility of confusion and
incorrect attachment on refitting. 7
To remove the fuel pump, first disconnect
the battery negative (earth) lead (refer to
Chapter 5A, Section 1).
8 Where applicable, remove the air cleaner to
improve access to the fuel pump (see Sec-
tion 2).
9 Disconnect the fuel hoses from the fuel
pump, noting their respective connections for
refitting. Where quick-release couplings are
used on the fuel hoses, release the protruding
locking lugs on each union, by squeezing
them together and carefully pulling the
coupling apart. Use rag to soak up any spilt
fuel. Where the unions are colour-coded, the
pipes cannot be confused. Where both unions
are the same colour, note carefully which pipe
is connected to which, and ensure that they
are correctly reconnected on refitting. Plug
the hoses to prevent fuel spillage and the
ingress of dirt.
10 Unscrew and remove the retaining bolts
or nuts (as applicable) and remove the fuel
pump.
11 Recover the gasket/spacer (see
illustration) and if required, withdraw the
pump operating pushrod (CVH engines only).
12 Thoroughly clean the mating faces on the
pump and engine.
Refitting
13 Refit in the reverse order of removal. Be
sure to use a new gasket, and tighten the
securing bolts/nuts securely. Ensure that the
hoses are correctly and securely reconnected.
If they were originally secured with crimped
type hose clips, discard them and fit
screw type clips. Where quick-release
couplings are fitted, press them together until
the locking lugs snap into their groove.
14 When the engine is restarted, check
the pump connections for any signs of fuel
leaks.
8 Fuel tank - removal,
inspection and refitting
3
Note: Refer to the warning note in Section 1
before proceeding.
Removal
1 Run the fuel level as low as possible prior to
removing the tank.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Remove the fuel filler cap, then syphon or
pump out the remaining fuel from the fuel tank
(there is no drain plug). The fuel must be
emptied into a suitable container for storage.
4 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and vehicle support” ). Remove
the rear roadwheels.
5 Unclip and disconnect the fuel feed and
return hoses located in front of the fuel tank,
and allow any residual fuel to drain into a
Fuel system – carburettor engines 4A•5
7.6 Fuel pump and fuel vapour separator
arrangement on HCS engine (shown from
below)
7.1b Fuel pump assembly fitted to CVHengines (securing nuts arrowed)
A Fuel feed from tank
B Fuel return to tank
C Fuel feed to carburettor7.1a Fuel pump location on HCS engine (shown from below)
A Fuel inlet hose
B Fuel return hose to tank
C Fuel outlet hose to carburettor
D Pump securing bolts
7.11 Gasket/spacer fitment on HCS
engine. Note position of the lug (arrowed)
4A
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container which can be sealed (see
illustration) . Where quick-release couplings
are used on the fuel hoses, release the
protruding locking lugs on each union, by
squeezing them together and carefully pulling
the coupling apart. Note that the fuel supply
hose couplings are identified by a white
colour band and the return hose couplings by
a yellow colour band.
6 Disconnect the filler neck sensing pipe
connection from the rear of the tank (see
illustration) .
7 Support beneath the tank to hold it in
position and remove its four securing bolts
(see illustration) .
8 Partially lower the fuel tank and disconnect
the ventilation tube from the tank top surface
and also disconnect the sender unit multi-
plug. The filler pipe should release from its
fuel tank seal location as the tank is
withdrawn.
Inspection
9 Whilst removed, the fuel tank can be
inspected for damage or deterioration.
Removal of the sender unit (see Section 9) will
allow a partial inspection of the interior. If the
tank is contaminated with sediment or water,
swill it out with clean petrol. Do not under any
circumstances undertake any repairs on a
leaking or damaged fuel tank; this work must
be carried out by a professional who has
experience in this critical and potentially-
dangerous work.
10 Whilst the fuel tank is removed from the
vehicle, it should not be placed in an area
where sparks or open flames could ignite the
fumes coming out of the tank. Be especially
careful inside garages where a natural-gas
type appliance is located, because the pilot
light could cause an explosion.
11 Check the condition of the filler pipe seal
in the fuel tank, and renew it if necessary.
Refitting
All models
12 Refitting is a reversal of the removal
procedure. Apply a light smear of grease to the
filler pipe seal, to ease fitting. Ensure that all
connections are securely fitted. Where quick-
release fuel couplings are fitted, press them together until the locking lugs snap into their
groove. If evidence of contamination was
found, do not return any previously-drained
fuel to the tank unless it is carefully filtered first.
9
Fuel gauge sender unit -
removal and refitting
3
Note: Ford specify the use of their service tool
23-014 (a large box spanner with projecting
teeth to engage the fuel gauge sender unit
retaining ring’s slots) for this task. While
alternatives are possible, in view of the difficulty
experienced in removing and refitting the
sender unit, owners are strongly advised to
obtain the correct tool before starting work. The
help of an assistant will be required. Refer to the
warning note in Section 1 before proceeding.
Removal
1 Remove the fuel tank as described in
Section 8.
2 Engage the special tool into the sender unit
then carefully turn the sender unit and release
it from the top of the tank.
Refitting
3 Refit the sender unit in the reverse order of
removal. Be sure to fit a new seal, and
lubricate it with a smear of grease to prevent it
from distorting when fitting the sender unit.
10 Fuel tank ventilation tube -
removal and refitting
3
Note: Refer to the warning note in Section 1
before proceeding.
Removal
1 The fuel tank ventilation tube runs from the
top surface of the fuel tank to the combined roll-
over/anti-trickle-fill valve assembly mounted in
the left-hand rear wheelarch (see illustration).
Its purpose is to eliminate any possibility of
vacuum or pressure build-up in the fuel tank.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
3 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and vehicle support” ). Remove
the left-hand rear roadwheel.
4 Support the fuel tank from underneath on a
suitable jack, using a large thick sheet of
board to spread the weight, then undo and
remove the four fuel tank securing bolts.
5 Lower the fuel tank slightly in such a manner
so as to allow access to disconnect the
ventilation tube from the tank top surface.
Ensure that the fuel tank does not foul or strain
any adjacent components as it is lowered;
take appropriate action, as necessary.
6 Disconnect the ventilation tube from the
combined roll-over/anti-trickle-fill valve, release
the tube from its retaining clips and remove.
Refitting
7 Refitting is a reversal of the removal
procedure, ensuring that the fuel tank filler
pipe is located correctly with the tank.
11 Fuel tank filler pipe -
removal and refitting
3
Note: Refer to the warning note in Section 1
before proceeding.
Removal
1 Remove the fuel tank as described in
Section 8.
4A•6 Fuel system – carburettor engines
10.1 Combined roll-over anti-trickle-fill valve assembly
A Tube ventilating to atmosphere
B Ventilation tube from fuel tank
8.7 Fuel tank securing bolts (arrowed)8.6 Filler neck sensing pipe connection at the rear of the fuel tank
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8.5 Fuel feed and return pipe connections
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2Remove the filler cap surround (see
illustration) .
3 Disconnect the ventilation tube from the
combined roll-over/anti-trickle-fill valve,
release the ventilation tube from its retaining
clips and detach the valve from the vehicle.
4 Remove the filler pipe securing bolt, then
twist and withdraw the filler pipe unit.
5 Prior to refitting, check the condition of the
filler pipe seal in the fuel tank and renew if
necessary.
Refitting
6 Refitting is a reversal of the removal
procedure, but apply a light smear of grease
to the filler pipe seal to aid filler pipe entry.
12 Carburettor (Weber TLM) -
description
The carburettor is of the single (fixed)
venturi downdraught type, featuring a fixed
size main jet system with a mechanically-
operated accelerator pump and vacuum-
operated power valve to provide optimum
fuelling. A manually-operated choke system is
fitted, featuring a vacuum-operated pull-down
mechanism which brings the choke partially
off during conditions of high manifold
vacuum. An anti-dieseling (fuel cut-off) solenoid
(where fitted) prevents the possibility of
engine run-on when the ignition is switched
off. Idle speed and mixture adjustment
procedures are described in Chapter 1, but it
is important to note that accurate adjustments
can only be made using the necessary
equipment.
13 Carburettor (Weber TLM) -
fast-idle speed adjustment
4
Note: Before carrying out any carburettor
adjustments, ensure that the spark plug gaps
are set as specified, and that all electrical and
vacuum connections are secure. To carry out
checks and adjustments, an accurate
tachometer and an exhaust gas analyser (CO
meter) will be required.
1 Check the idle speed and mixture settings
are as specified (as described in Chapter 1).
These must be correct before
checking/adjusting the fast-idle speed.
2 With the engine at its normal operating
temperature, and a tachometer connected in
accordance with the manufacturer’s
instructions, remove the air cleaner (if not
already done) as described in Section 2.
3 Actuate the choke by pulling its control
knob fully out, then start the engine.
4 Hold the choke plate open using a 5.0 mm
twist drill held between the plate and the venturi, and record the fast-idle speed
achieved. If adjustment is necessary, turn the
fast-idle adjusting screw until the specified
speed is obtained
(see illustration).
5 Re-check the fast-idle and basic idle
speeds.
6 On satisfactory completion of the
adjustment, stop the engine, disconnect the
tachometer and CO meter then refit the air
cleaner.
7 Remove the bridging wire from the radiator
cooling fan thermal switch multi-plug, and
reconnect the multi-plug to the thermal
switch.
14 Needle valve and float (Weber
TLM carburettor) - removal,
refitting and adjustment
4
Note: Refer to the warning note in Section 1
before proceeding. New gaskets and a washer
(seal) will be required when reassembling. A
tachometer and an exhaust gas analyser (CO
meter) will also be required to check the idle
speed and mixture settings on completion.
Removal and refitting
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 Clean the exterior of the carburettor, then
disconnect the fuel feed hose.
4 Disconnect the choke cable and the choke
vacuum hose. 5
Remove the four screws securing the
carburettor upper body (two of these screws
are Torx head type), and detach it. Note that
the carburettor lower body is now loose
on the inlet manifold.
6 Tap out the float retaining pin, remove the
float and withdraw the needle valve. Unscrew
the needle valve housing, as required, noting
washer fitment.
7 Inspect the components for damage and
renew as necessary. Check the needle valve
for wear, and check the float assembly for
leaks by shaking it to see if it contains petrol.
Whilst accessible, clean the float chamber
and jets (refer to Section 17).
8 Using a new washer, refit the needle valve
housing.
9 Refit the needle valve, float and retaining
pin, ensuring that the tag on the float engages
between the ball and clip on the needle valve.
10 Before refitting the carburettor upper
body, check and if necessary adjust the float
level as described in paragraph 15 to 18. Also
check the float and needle valve for full and
free movement.
11 Clean the gasket contact faces (including
the inlet manifold) then, using new gaskets for
the carburettor upper body and the inlet
manifold faces, refit the carburettor upper
body and secure the carburettor assembly to
the inlet manifold.
12 Reconnect the choke vacuum hose. If the
fuel feed hose was originally secured with a
crimped type clip, discard this and secure the
fuel feed hose with a nut and screw type clip.
13 Reconnect and adjust the choke cable,
then refit the air cleaner.
14 Reconnect the battery negative lead, start
and warm up the engine then check the idle
speed and mixture settings as described in
Chapter 1.
Float level adjustment
15 With the carburettor upper body removed
as described in paragraphs 1 to 5 inclusive,
proceed as follows.
16 Hold the carburettor upper body in the
position shown (see illustration) , ensuring
that the needle valve is shut off. Fit the new
upper body gasket to the carburettor upper
Fuel system – carburettor engines 4A•7
13.4 Fast-idle speed adjusting screw (arrowed) (Weber TLM carburettor)
11.2 Removing the filler cap surround
14.16 Float level adjustment (Weber TLM carburettor)
A Adjusting tag
B Float level setting dimension
4A
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body, then measure the distance between the
gasket and the step on the float.
17If the measurement is not as specified,
adjust by bending the tag on the float, then re-
check.
18 Refitting should be carried out in
accordance with paragraphs 11 to 14
inclusive.
15 Carburettor (Weber TLM) -
removal and refitting
4
Note: Refer to the warning note in Section 1
before proceeding. New gaskets will be
required when reassembling. A tachometer
and an exhaust gas analyser (CO meter) will
also be required to check the idle speed and
mixture settings on completion.
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 Disconnect the accelerator inner and outer
cable from the carburettor (Section 3).
4 Disconnect the choke inner and outer cable
from the carburettor (Section 6).
5 Disconnect the fuel feed hose from the
carburettor, and plug its end to avoid spillage
and prevent dirt ingress. If a crimped type
hose clip is fitted, cut this free taking care to
avoid damage to the hose.
6 Where applicable, disconnect the electrical
lead from the anti-dieseling (fuel cut-off)
solenoid, and all relevant carburettor vacuum
pipes (having labelled them for correct
subsequent refitting).
7 Remove the two Torx head screws securing
the carburettor to the inlet manifold, then
withdraw it from the vehicle (see illustration).
Refitting
8Clean the inlet manifold and carburettor
gasket mating faces.
9 Refit in the reverse order of removal. Fit a
new gasket, and tighten the retaining screws
securely. Ensure that the fuel supply hose
connection to the carburettor is securely fitted, using a new screw type retaining clip.
10
Reconnect the accelerator cable, and
adjust it as described in Section 3.
11 Reconnect the choke cable, and adjust it
as described in Section 6.
12 Refer to Section 2 and refit the air cleaner.
13 When the battery is reconnected, start
and warm up the engine then check the idle
speed and mixture settings as described in
Chapter 1.
16 Accelerator pump diaphragm (Weber TLM carburettor) -
removal and refitting
4
Note: Refer to the warning note in Section 1
before proceeding.
Removal
1 Remove the carburettor as described in
Section 15 and place it on a clean flat work
surface.
2 Remove the accelerator pump cover
retaining screws and detach the cover.
3 Withdraw the diaphragm and spring. Check
the diaphragm for damage, and renew if
evident.
Refitting
4 Clean the carburettor and cover mating
faces. 5
Refit the spring and diaphragm to the
carburettor, aligning the diaphragm with its
cover retaining screw holes. Position the
actuating lever on its cam, then carefully
press the cover against the diaphragm and
secure with its retaining screws.
6 Refit the carburettor as described in
Section 15.
17 Carburettor (Weber TLM) -
dismantling, cleaning,
inspection and reassembly
4
Note: Refer to the warning note in Section 1
before proceeding. Check parts avail-
ability before dismantling. If possible, obtain
an overhaul kit containing all the relevant
gaskets, seals, etc, required for reassembly
prior to dismantling the carburettor.
Dismantling
1 Remove the carburettor as described in
Section 15 and place it on a clean flat work
surface.
2 Clean the exterior of the carburettor, then
undo the two retaining screws and lift off the
upper carburettor body (see illustration).
3 Remove the float and needle valve from the
carburettor upper body, as described in
Section 14.
4 Remove the accelerator pump components
4A•8 Fuel system – carburettor engines
17.2 Exploded view of the carburettor (Weber TLM)
15.7 Removing one of the two Torx head
screws (arrowed) securing the carburettor to the inlet manifold (Weber TLM
carburettor)
1595Ford Fiesta Remake
A Upper body
B Choke mechanism
C Accelerator pump
assembly
D Accelerator pump discharge tube
E Fast-idle speed adjusting screw
F Throttle housing
G Idle speed adjusting screw
H Anti-dieseling (fuel cut-off) solenoid
J Power valve assembly
K Float
L Idle mixture adjusting screwprocarmanuals.com
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as described in Section 16. The power valve
assembly can also be removed in a similar
fashion.
5Prise free the accelerator pump discharge
tube, but take care not to damage it or the
carburettor body.
6 Remove the jets and emulsion tubes as
required, making careful notes of their
respective locations for reassembly.
Cleaning and inspection
7 Soak out the fuel in the float chamber using
a clean rag; this must be safely disposed of.
Clean the float chamber, jets, drillings and
passages with clean petrol. The careful use of
an air line (or footpump) is ideal to blow out
the upper and lower bodies. Never use a
piece of wire for cleaning purposes.
8 Examine all of the carburettor components
for signs of damage or wear, paying particular
attention to the diaphragms, throttle spindle
and plates, and needle valve. Renew all
diaphragms, sealing washers and gaskets as
a matter of course.
Reassembly
9 Refit the emulsion tubes and jets to their
locations as noted during dismantling.
10 Refit the accelerator pump discharge
tube.
11 Refit the accelerator pump and power
valve assemblies as described in Section 16.
12 Refit the needle valve and the float, and
adjust the float setting as described in Sec-
tion 14.
13 Locate a new gasket onto the mating
face, then refit the carburettor upper body to
the main body. As they are reassembled, take
care not to snag the float on the carburettor
main body. Fit and tighten the retaining
screws to secure.
14 On completion, refit the carburettor as
described in Section 15.
18 Carburettor (Weber TLDM) -
description
The carburettor is of twin venturi,
downdraught type, featuring a fixed size main
jet system, adjustable idle system, a
mechanically-operated accelerator pump, and
a vacuum-operated power valve. A manually-
operated cold start choke is fitted, and a
throttle kicker is used on certain models.
In order to comply with emission control
regulations and maintain good fuel
consumption, the main jets are calibrated to
suit the 1/4 to 3/4 throttle range. The power
valve is therefore only used to supply
additional fuel during full-throttle conditions. The accelerator pump is fitted to ensure a
smooth transmission from the idle circuit to
the main jet system. As the accelerator pedal
is depressed, a linkage moves the diaphragm
within the accelerator pump, and a small quantity of fuel is injected into the venturi, to
prevent a momentary weak mixture and
resultant engine hesitation.
The manually-operated choke features a
vacuum-operated pull-down mechanism
which controls the single choke plate under
certain vacuum conditions. On CTX automatic transmission models,
the throttle kicker acts as an idle speed
compensator for when the transmission shift
lever positions R, D or L are selected. The
throttle kicker is operated by vacuum supplied
from the inlet manifold. When the appropriate
transmission shift lever position is selected,
the throttle kicker control solenoid allows the
vacuum to pass to the throttle kicker which
maintains the idle speed by means of a
diaphragm and mechanical linkage. On manual transmission models, the
throttle kicker (when fitted) acts as a damper
by slowing down the closing action of the
throttle plate. Under deceleration, this
maintains the combustion of the air/fuel
mixture entering the cylinders, thus improving
the exhaust emission levels. A vacuum
sustain valve controls the carburettor-sourced
vacuum applied to the throttle kicker unit; this
allows the vacuum slowly to decay, allowing
normal engine idling speed to be achieved. An anti-dieseling (fuel cut-off) solenoid is
fitted to prevent the possibility of the engine
running on after the ignition is switched off. Idle speed and mixture adjustment
procedures are described in Chapter 1, but it
is important to note that accurate adjustments
can only be made using the necessary
equipment.
19 Carburettor (Weber TLDM) -
fast-idle speed adjustment
4
Note: Before carrying out any carburettor
adjustments, ensure that the spark plug gaps
are set as specified, and that all electrical and
vacuum connections are secure. To carry out
checks and adjustments, an accurate
tachometer and an exhaust gas analyser (CO
meter) will be required.
1 Check the idle speed and mixture settings are as specified (as described in Chapter 1).
These must be correct before
checking/adjusting the fast-idle speed.
2
With the engine at its normal operating
temperature, and a tachometer connected in
accordance with the manufacturer’s
instructions, switch the engine off, then
remove the air cleaner (if not already done) as
described in Section 2.
3 Actuate the choke by pulling the control
knob fully out, then start the engine and note
the engine fast-idle speed. Compare it with
the specified speed.
4 If adjustment is required, turn the fast-idle
adjusting screw clockwise to decrease, or
anti-clockwise to increase, the fast-idle speed
(see illustration) .
5 Recheck the fast-idle and basic idle
speeds.
6 On completion of the adjustment, stop the
engine, detach the tachometer and CO meter,
reconnect the radiator cooling fan lead, and
refit the air cleaner.
20 Needle valve and float (Weber
TLDM carburettor) - removal,
refitting and adjustment
4
Note: Refer to the warning note in Section 1
before proceeding. New gaskets and a washer
(seal) will be required when reassembling. A
tachometer and an exhaust gas analyser (CO
meter) will also be required to check the
idle speed and mixture settings on
completion.
Removal and refitting
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the air cleaner as described in
Section 2.
3 Clean the exterior of the carburettor, then
disconnect the fuel supply hose and the anti-
dieseling solenoid wiring.
4 Disconnect the choke control cable.
5 Undo and remove the six retaining screws
(four of which are Torx type) and carefully lift
the carburettor upper body clear (see
illustrations) .
6 Invert and support the upper body of the
carburettor for access to the float and pivot.
Fuel system – carburettor engines 4A•9
19.4 Fast-idle speed adjusting screw (arrowed) (Weber TLDM carburettor)
4A
1595Ford Fiesta Remake
20.5a Remove the carburettor upper body securing screws . . .
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Lightly tap out the float pivot pin, then
withdraw the float, taking care not to distort
the arms of the float (see illustrations).
7 Unscrew the needle valve housing, and
extract it from the carburettor upper body.
Collect the washer from the threads of the
needle valve housing.
8 Clean and inspect the components for
signs of damage or wear, particularly the pivot
holes in the float arm. Check the float for signs
of leakage, by shaking it to see if it contains
fuel. Clean the float chamber and jets (refer to
Section 24 for details). Renew any
components as necessary.
9 Fit a new washer over the needle valve
housing threads, and then carefully screw the
valve unit into position in the upper body.
10 Refit the needle valve, float and retaining
pin, ensuring that the tag on the float engages
with the ball and clip of the needle valve.
11 Before refitting the upper body to the
carburettor, check and if necessary adjust the
float level as described in paragraphs 16
to 18. Also check the float and needle valve
for free movement.
12 Clean the gasket contact faces, then
locate a new gasket and refit the upper body
to the carburettor.
13 Reconnect the fuel supply hose, anti-
dieseling solenoid wiring and the choke cable.
Adjust the choke cable as described in
Section 6. If the fuel hose was originally
secured with a crimped type clip, discard it
and fit a screw type clip. 14
Refit the air cleaner as described in
Section 2.
15 Reconnect the battery earth lead, then
restart the engine and check the idle speed
and mixture settings. Adjust if necessary as
described in Chapter 1.
Float level adjustment
16 With the carburettor upper body removed
as described in paragraphs 1 to 5 inclusive,
proceed as follows.
17 Support the carburettor upper body
vertically, ensuring that the needle valve is
shut off. Locate the new upper body gasket
onto the carburettor upper body, then
measure the distance between the gasket and
the bottom of the float (see illustration).
18 If the measurement is not as specified,
adjust the setting by carefully bending the tag
on the float as required, then recheck.
19 Refit with reference to paragraphs 12
to 15 inclusive.
21 Throttle kicker unit (Weber TLDM carburettor) - removal,
refitting and adjustment
4
Note: A tachometer and exhaust gas analyser
(CO meter) will be required to check and make
any adjustment necessary.
Removal and refitting
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Refer to Section 2 and remove the air
cleaner.
3 Detach the vacuum hose from the kicker
unit. Undo the two retaining screws, detach
the linkage and remove the kicker unit (see
illustration) .
4 Refitting the kicker unit is a reversal of the
removal procedure. If the unit is to be
checked for adjustment, loosely locate the air
cleaner, reconnect the inlet air temperature
sensor multi-plug and the battery earth lead,
then proceed as follows.
Adjustment
5 Start and run the engine up to its normal
operating temperature (at which point the
cooling fan will start to operate) then switch
the engine off.
6 Remove the air cleaner again, then detach
the wiring connector of the cooling fan
thermostatic switch. Bridge the terminals in
the connector with a suitable piece of wire to
actuate the cooling fan and keep it running.
Start the engine and run it at 3000 rpm for
30 seconds to stabilise it, then release the
throttle and check (and if necessary adjust)
the idle speed and mixture settings as
described in Chapter 1. Stop the engine.
4A•10 Fuel system – carburettor engines
21.3 General view of throttle kicker
arrangement (Weber TLDM carburettor)
A Tamperproof plug covering adjusting point
B Throttle kicker securing screws
C Vacuum supply pipe20.17 Float level adjustment (Weber TLDM carburettor)
A Float level setting dimension
B Adjusting tag
20.6c Remove the needle valve housing and its washer
20.6b . . . then detach the float and needle valve20.6a Slide out the float retaining pin . . .20.5b . . . then detach the carburettorupper body
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